ibar hxa catalogue

busbar trunking system

Product Catalogue

Resin Insulated Aluminium ConductorsHigh Power (800A - 5000A)

HXA

ISO9001 - ISO14001OHSAS 18001

IBAR (EMEA) LtdWestmorland Business Park

KendalCumbria

LA9 6NSUK

t. +44 (0) 1539 797604f. +44 (0) 1539 724384

e. [email protected]

Registered in England No. 08695995

busbar trunking system

Rob AndersonBusiness Development Manager

m. +44 (0) 7703 679511t. +44 (0) 1539 797604e. [email protected]

Alice WebsterBusiness Development Manager


Colin ThatcherSales Manager


Dean BradshawSales Director


Get in touch!

2 Contents

1 Introduction 3

2 Product Library 4-13

3 Technical Overview 15

3.1 - 3.14 Technical Parts Detail 16-33

4 Applications Engineering 34

5 iControl Integration 34

6 Parts Numbering Guide 35

1 - IntroductionA truly end to end solution

HXA is part of the IBAR HX range of high power busbar trunking systems.

HXA utilises a sandwich arrangement of individually insulated busbars (using a specialist epoxy resin coating)which are contained within a unique two piece, IP55 rated, Aluminium trunking / housing.

The HX range is also available with a HDHC Copper (99.9%) BS EN 13601 conductor.

About IBAR

IBAR (EMEA) Ltd is part of the Mardix Group of companies.

The IBAR range of power distribution busbar trunking system products has been developed to meet the growing demands of the critical power industry.

Employing innovative designs to improve performance and reduce costs we have invested in the best available technologies to ensure our finished product is of the highest quality.

Our highly skilled engineering teams and applications engineers can tailor a solution to meet even the most demanding requirements.

IBAR employs more than 45 years of leading-edge experience incorporating all the quality, reliability and innovation for which our group is renowned.

All IBAR product is manufactured within the UK to the latest British Standards (BS EN 61439-6).

From small scale to multi million pound projects, we hope you will make IBAR your first choice for busbar.

22 3

Ref: IBAR-HXA-CATPublished 05/06/14Revision 1.0.0Author: AB

Tap-off Box

Expansion Unit

Distribution Length

Termination Cap

Transformer Flange

Offset

Edgewise Elbow

LV Switchboard

Transformer Housing

Panel Flange Flatwise

Feeder Length

Joint Pack

2 - Product LibraryA solution for the most challenging buildings

Feeder Busbar

There are many applications which require the ability to move large amounts of power; the most common of which is the transmission of power between transformers and low voltage switchboards and then further sub-distribution.

IBAR’s HXC range provides a high-power transmission busbar solution with busbar ratings ranging from 1000A up to 6300A. Each rating type can be supplied with between 3 and 6 conductive bars arranged in a sandwich type construction and insulated with a specialist resin coating. Configurations are available for 3-phase, 3-phase and neutral / protected earth (for loads susceptible to harmonic distortion / leakage currents) and optional double rated neutral.

Distribution Busbar

Busbar trunking systems are favoured greatly over traditional fixed position cable installations due to the flexibility of the available tap-off locations.

The standard straight 3m lengths can be fitted with up to four specially engineered tap-off points at standard or custom locations.

Each tap-off location features high-integrity weld-bonded copper connection tabs. This high-quality, high-conductivity connection means only a single tap-off location is required for tap-offs of up to 630A.

Available Ratings Available Configurations *

* All feature Case Earth

2.1 Feeder Lengths

2.2 Distribution Lengths

2.3 Flatwise Elbow 2.4 Edgewise Elbow 2.5 Custom Elbow

Up to 4notap-off pointsper 3m length

Standard lengths:

• 4m• 3m• 2m• 1m

Puzzled? Speak to our expert applications engineers now!

t. +44 (0) 1539 797604e. [email protected]

5

800A1000A1250A1400A1600A

2000A2500A3200A4000A5000A

TPTP&NTP&ETP&N&ETP&2NTP&2N&E

See the HX Range Tap-offs Product Catalogue for

more information

2.12 Expansion Unit

2.15 End Feeder Unit 2.16 Termination Cap 2.17 Centre Feeder

2.6 Flatwise Offset 2.7 Combination Elbow / Offset

2.8 Transformer / Parallel Flange 2.9 Panel Flange

2.10 Combination Panel Flange / Elbow 2.11 ‘T’ Section

2.13 Joint Packs

6 7

2.18 Edgewise Installation Brackets 2.19 Flatwise Installation Brackets

2.20 Vertical Hangars

2.22 Fire Barrier 2.23 Transition Unit (Cast Resin to Internal)

2.24 Final Connection Lengths

“ “No problems,

just solutions

Express lead timestypically < 1 week!

2.25 Tap-off Boxes

8 9

See the HX Range Tap-offs Product Catalogue for

more information

Specialistepoxy

resininsulation

6101AAluminium

Unique two piece IP55 Aluminium

trunking case

Joint pack

Polyester powder coatedfinish

Double headed

shearnut

10 11

See the HXC Range Product Catalogue for Copper Conductor Systems

Construction Types (Single, Double and Triple)

3 - Technical Overview800 1000 1250 1400 1600 2000 2500 3200 4000 5000

Rated operating voltage Ue [V]Rated insulation voltage Ui [V]Frequency f [Hz]Degree of protection IPCasing materialConductor arrangementConductor profileConductor materialConductor surface treatmentConductor Insulation

800 1000 1250 1400 1600 2000 2500 3200 4000 5000

Casing overall dimensions W x H [mm] 155 x 105 155 x 140 155 x 170 155 x 185 155 x 205 155 x 260 155 x 370 155 x 440 155 x 550 155 x 720Conductor dimensions W x D [mm] 55 x 6 80 x 6 110 x 6 125 x 6 145 x 6 200 x 6 2 x 110 x 6 2 x 145 x 6 2 x 200 x 6 3 x 160 x 6Conductor CSA CSA [mm2] 322 472 652 742 862 1192 1305 1725 2385 2857Weight (3 conductors) p [kg/m] 6.0 7.6 9.2 10.1 11.3 14.5 18.4 22.6 29.0 36.6Weight (4 conductors) p [kg/m] 6.8 8.8 10.9 12.0 13.5 17.6 21.8 27.0 35.2 43.8Weight (5 conductors) p [kg/m] 7.6 10.0 12.6 13.9 15.8 20.8 25.2 31.6 41.6 51.3Weight (6 conductors) p [kg/m] 8.5 11.2 14.3 15.9 18.0 23.9 28.6 36.0 47.8 59.1

800 1000 1250 1400 1600 2000 2500 3200 4000 5000

Rated short-time current for three-phase fault (1s)

Icw [kA]rms 25 50 65 65 65 80 80 100 120 120

Allowable peak current for three-phase fault

Ipk [kA] 55 110 143 143 143 176 176 220 264 264

Rated short-time current for single-phase fault (1s)

Icw [kA]rms 15 30 39 39 39 48 48 60 72 72

Allowable peak current for single-phase fault

Ipk [kA] 33 66 85.8 85.8 85.8 100.8 100.8 132 158.4 158.4

Rated short-time protection current (1s)

Icw [kA]rms 15 30 39 39 39 48 48 60 72 72

Rated conditional protection current

Icc [kA] 15 30 39 39 39 48 48 60 72 72

Protection circuit peak rated current

Ipk [kA] 33 66 85.8 85.8 85.8 100.8 100.8 132 158.4 158.4

Dimensions

Fault Rating

Plain (Tinned optional)Epoxy UL94 (V0)

Rated Current ln [A]

50/6010001000

SandwichAluminium

55

Rect. Full radius cornerElectrical Grade 6101A

Standard lengths (x): 4m, 3m, 2m, 1mMinimum length (x): 0.5m Maximum length (x): 4m

12 133.1 - Straight Lengths

Straights are one of the most common parts of any trunking system.Custom lengths can be manufactured to suit each application requirement within the ranges below. Feeder type busbar is used for end to end transmission and distribution type incorporates tapping outlets for connection of tap off units.

In most cases it is preferred that the application of the product leave straights as the final site measure pieces to enable faster turnaround times and greater flexibility.

Straight Lengths

Single - 800A - 2000A

Double - 2500A - 4000A

Triple - 5000Abusbar trunking system

HXC HXA

Edgewise Elbows

3.3 - Edgewise Elbows

Edgewise elbows are used to make directional changes to busbar runs usually at 90o to the direction of travel.

In addition to providing left and right elbows in standard 90o it is possible to have custom angles manufactured (please contact our applications and engineering team for further information).

See the table below for further information on sizes available.

Typical Arrangement

Flatwise Elbows

3.2 - Flatwise Elbows

Flatwise elbows are used to make directional changes to busbar runs usually at 90o to the direction of travel.

In addition to providing left and right elbows in standard 90o it is possible to have custom angles manufactured (please contact our applications and engineering team for further information).

See the table below for further information on sizes available.

Minimum Maximum

X Y X & Y X & Y

800 Single 350 350 250 7001000 Single 350 350 250 7001250 Single 350 350 250 7001400 Single 350 350 275 7001600 Single 350 350 300 7002000 Single 350 350 325 7002500 Double 500 500 375 7003200 Double 500 500 415 7004000 Double 500 500 485 7005000 Triple 600 600 600 600

Busbar Rat ing (Amps)C onst ruct ion

Type

St andard

Typical Arrangement

14 15

Minimum Maximum

X Y X & Y X & Y


Busbar Rat ing (Amps)St andardC onst ruct ion

Type

Flatwise Offsets

3.4 - Flatwise Offsets

Offsets are commonly used to avoid small obstructions and obstacles that the use of two elbows would make inefficient.

The four variants of offset are edgewise left & right and flatwise left & right.

See table below for size options available.

Typical Arrangement

Edgewise Offsets

3.5 - Edgewise Offsets

Offsets are commonly used to avoid small obstructions and obstacles that the use of two elbows would make inefficient.

The four variants of offset are edgewise left & right and flatwise left & right.

See table below for size options available.

Typical Arrangement

16 17

Minimum Maximum Minimum Maximum

X Y X & Y X & Y Z Z

800 Single 350 350 250 650 50 7001000 Single 350 350 250 650 50 7001250 Single 350 350 250 650 50 7001400 Single 350 350 275 650 50 6751600 Single 350 350 300 650 50 6402000 Single 350 350 325 650 50 5702500 Double 500 500 375 650 50 6753200 Double 500 500 415 650 50 6404000 Double 500 500 485 650 50 5705000 Triple 550 550 550 650 50 640

Busbar Rat ing (Amps)

C onst ruct ion Type

St andard Minimum Maximum Minimum Maximum

X Y X & Y X & Y Z Z




St andard

X Y X Y

800 Single 115 250 800 5001000 Single 115 250 800 5001250 Single 115 250 800 5001400 Single 140 275 800 5001600 Single 165 300 800 5002000 Single 190 325 800 5002500 Double 240 375 800 5003200 Double 280 415 800 5004000 Double 350 485 800 5005000 Triple 441.5 600 441.5 600


TypeMinimum Maximum

Panel Flange

3.6 - Panel Flange

Panel flanges are the standard fittings used to make connections to other items of LV equipment such as switchboards and transformers etc.

Each rating of flange has set dimensions for the cutout and fixing points that are supplied on drawings with each unit.

Phase rotation from other equipment to a busbar system needs careful coordination and all phase details must be highlighted and approved at design stage.

Panel flanges can also be manufactured with integrated 90o change of direction to accommodate low headroom applications.

Typical Arrangement

Flange Elbow Flatwise

3.7 - Flange Elbow Flatwise


Panel flanges with integrated 90o change of direction allow for low headroom applications and are available both in flatwise and edgewise formats.

Each rating of flange has set dimensions for the cut out & fixing points identical to that of straight type units the details of which are supplied on drawings with each unit.


18 19

Typical Arrangement

St andard Minimum Maximum

X X X

800 Single 250 250 8001000 Single 250 250 8001250 Single 250 250 8001400 Single 250 250 8001600 Single 250 250 8002000 Single 250 250 8002500 Double 250 250 8003200 Double 250 250 8004000 Double 250 250 8005000 Triple 250 250 800



X Y

800 Single 1000 3751000 Single 1000 3751250 Single 1000 3751400 Single 1000 3751600 Single 1000 3752000 Single 1000 3752500 Double 1000 5503200 Double 1000 5504000 Double 1000 5505000 Triple 1250 675

Busbar Rat ing (Amps) C onst ruct ion TypeSt andard

X Y X Y



TypeMinimum Maximum

3.8 - Flange Elbow EdgewiseFlat Tee

3.9 - Flat Tee

Tee units are used to make branched busbar runs. The tee units create a 90o branch to accomodate multiple end supply points from a single source and can, in certain applications, be a more efficient way of creating a widespread distribution backbone.

Tee’s are available in compact form in flatwise construction.

Typical Arrangement

20 21

Flange Elbow Edgewise


Panel flanges with integrated 90o change of direction allow for low headroom applications and are available both in flatwise and edgewise formats.

Each rating of flange has set dimensions for the cut out & fixing points identical to that of straight type units the details of which are supplied on drawings with each unit.


Typical Arrangement

St andard St andard St andard

A B C

600 600 350600 600 350600 600 350600 600 350600 600 350600 600 350600 800 650600 800 650600 800 650600 800 8005000


8001000

4000

125014001600200025003200

Fire Barrier

3.10 - Fire Barriers

Fire barrier units are manufactured as a complete assembly on standard length sections (see table) using calcium silicate based material that is classified as non-combustible according to EN13501-1. The material is free from asbestos and quartz and is extremely lightweight with excellent insulating value, high mechanical strength and good heat resistance. The boards are designed for maximum service temperatures of up to 1050°C.

Due to the jacket design they can be installed on any length bar to accommodate applications that do not suit the use of a standard length section. But these must be highlighted during design phase to allow manufacture.

Fire penetration ratings of up to 240 minutes are available (S240) according to ISO 834-1 on all ratings of IBAR.

Typical Arrangement

End Feed

3.11 - End Feed

End feed units are used to connect cables to feed a busbar run. Typical use is in a building riser, either at the top or bottom but they are also found feeding horizontal systems.

Side and bottom glanding areas allow for the greatest flexibility when it comes to cabling the unit.

The size of an end feed is generally governed by the size, type and number of cables being connected, see below for the standard sizes available.

Special sizes and configurations can be designed to suit particular applications, please contact our applications engineering team for further details.

Typical Arrangement

22 23

A (mm) B (mm) C (mm) D (mm) W (mm) H (mm)




Typical Apert ure SizeF ire Barrier Dimensions

St andard St andard St andard

A B C

600 600 350600 600 350600 600 350600 600 350600 600 350600 600 350600 800 650600 800 650600 800 650600 800 8005000


800

250032004000

10001250140016002000

Centre Feed

3.12 - Centre Feed

Centre feed units are used to connect cables to feed a busbar run. As its name suggests the centre feed unit will be situated somewhere along the busbar run feeding power to both branches that connect.

Centre feed units can be used to supply any busbar configuration, building risers and horizontal systems.Side and bottom glanding areas allow for the greatest flexibility when it comes to cabling the unit.

The size of an end feed is generally governed by the size, type & number of cables being connected, see below for the standard sizes available.

Special sizes and configurations can be designed to suit particular applications, please contact our applications engineering team for further details.

Typical Arrangement

Hangars and Fixings

3.13 - Hangars and Fixings

Correct mounting of the busbar trunking run is a critical element of ensuring a trouble free system. The IBAR HX system has a range of mounting & clamping hardware that is fully compatible with the widely available Unistrut system.

Horizontal installations will make use of the universal fixing clamp that is able to accommodate flatwise and edgewise orientations and fixed clamps that are typically used on long straight runs where expansion needs to be controlled. Both of these clamps fit onto standard41x41mm Unistrut as illustrated below.

Vertical riser installations make use of the fixed clamps and proprietary spring brackets used to distribute load evenly across the building structure and isolate the bar from excessive vibration or building movement.

24 25

Typical Arrangements

Part Type Codes

CF Centre FeedCM CombinationEC End CapEF End FeedEX ExpansionFB Fire BarrierJP Joint PackLE Elbow EdgewiseLF Elbow FlatwiseNR Neutral RotationPF Panel FlangePR Phase RotationSD Straight DistibutionSF Straight FeederTF Tee FlatwiseTX Transformer FlangeZE Offset EdgewiseZF Offset Flatwise

Part Variant Codes

060 60min Rating120 120min Rating240 240min RatingCD Custom DownCL Custom LeftCR Custom RightCU Custom UpCX CustomLD Left DownwardsLU Left UpwardsRD Right DownwardsRU Right UpwardsSL Standard 90 LeftSR Standard 90 RightST StraightST1 Standard 1m StraightST2 Standard 2m StraightST3 Standard 3m StraightST4 Standard 4m Straight

Rating Codes

8 800A10 1000A12 1250A14 1400A16 1600A20 2000A25 2500A32 3200A40 4000A50 5000A63 6300A

# Bars / Poles

3 TP4 TP&N / TP&E5 TP&2N / TP&N&E6 TP&2N&E

busb

ar t

runk

ing

syst

em

5 0 0 0 0 0 0 0 1 8

Part No. HXC-16-4P-PF-ST

Serial No. 21347/001/14/001 B01

Current [InA] 1600

Voltage [Ue] 690

Frequency [fn] 50

RMS Fault [lcw] 65

IP Rating 55

# Bars / Poles 4 / TP&N

Neutral Rating 100%

Earth Rating 100% PE CASE

Complies With BS EN 61439-6

Designed and Made in Britain by IBAR (EMEA) Ltd

Unit 1, Westmorland Business Park, Kendal, Cumbria, LA9 6NS, UK.

www.ibar-emea.com t. +44 (0) 1539 797604 e. [email protected]

www.icontrol-cloud.com

iControl CloudTM

Service Tag

A

V

Hz

kA/1s

busb

ar t

runk

ing

syst

em

5 0 0 0 0 0 0 0 1 8Part No.HXC-16-4P-PF-ST

Serial No.21347/001/14/001 B01

Current [InA]1600

Voltage [Ue]690

Frequency [fn]50

RMS Fault [lcw] 65

IP Rating55

# Bars / Poles 4 / TP&N

Neutral Rating 100%

Earth Rating100% PE CASE

Complies With BS EN 61439-6





iControl CloudTM

Service Tag

A

V

Hz

kA/1s

busb

ar t

runk

ing

syst

em

5 0 0 0 0 0 0 0 1 8

Part No.

HXC-16-4P-PF-ST

Serial No.21347/001/14/001 B01

Current [InA]1600

Voltage [Ue]690

Frequency [fn]50

RMS Fault [lcw]65

IP Rating55

# Bars / Poles4 / TP&N

Neutral Rating100%

Earth Rating100% PE CASE

Complies WithBS EN 61439-6





iControl CloudTM

Service Tag

A

V

Hz

kA/1s

4 - Applications Engineering26 27

HX A 16 4P SF ST3- - - -

IBAR Range CodeHX = High Power

Conductor Type CodeA = Aluminium

C = Copper

Rating Code (A)16 = 1600A...

63 = 6300A

# Bars

Part Type CodeSF = Straight Feeder...PF = Panel Flange

Part Variant CodeST4 = Standard 4M ...ST3 = Standard 3M

6 - Parts Numbering Guide

5 - iControl Cloud IntegrationEvery piece of IBAR is fitted with an iControl Cloud tag, this enables components to be referenced within a particular busbar run together with arrangement drawings, commissioning reports and lifecycle servicing reports to be uploaded and retained for the life of the asset.

Access to iControl Cloud is provided free of charge to IBAR customers for the first year from Practical Completion(of the IBAR installation).

iControl Cloud can be extended to include any other asset, full details are available online at www.icontrol-cloud.com

The success of a busbar installation starts from the very moment that IBAR is specified, our team of driven and dedicated sales and application engineers are pro-active in making sure that you get what you want when you need it.

Our experienced team of in-house applications engineers are on hand to make using IBAR a hassle free process utilising a catalogue of standard and customisable parts they are able to create bespoke solutions tailored to the most demanding requirements.

Our teams work closely with other infrastructure and power system providers to coordinate critical elements such as phase orientation.

Typical process:

Building surveyProcure available floor plans, 3D models and supplement with site survey to confirm dimensions and assess obstructions.

Busbar layout drawingsGenerate and layout accurate 3D busbar runs using 3D CAD software to create BIM compliant models. Attention to positioning of tap off units, phase orientation and efficient installation.

Coordinate with infrastructure and other suppliersLiaison with third parties to confirm phase rotation and avoid infrastructure clashes during install. Installation teams are fully involved as part of the coordination process.

ApprovalEnsure key project stakeholders approval of equipment supply and busbar layout design prior to any non-standard parts manufacture.

Manufacture, delivery & installation Production drawings issued and manufacturing slots booked based on delivery & installation plan. Itemised parts delivered to site fully labelled to match installation drawings.

Site measuresOnce available for inspection any final connection pieces are confirmed, measured and manufactured. Delivery is then prioritised to suit the installation.

ibar hxa catalogue

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